Void Filling Material

Void filling material is used in many
distribution operations in the assembly of cases of mixed goods
from orders. The maximum weight for a mixed case should be is
about 35lbs (16Kg). Building mixed cases where the size ratios of
L=D=2W results in a case that has a moderate sized footprint for
handling on the packing workstation and conveyors. The L=2W
footprint allows for more opportunities for bracing randomly
sized objects than a square footprint would allow.

Eco Foam®
is a cornstarch-based, biodegradable and
water-soluble alternative to the conventional styrene
peanut. It is easy to flow and handle in the packing
station, however its tendency to settle and migrate
around the package ultimately makes it less than an ideal
void fill material if not used carefully and a bit more
liberally. Especially in larger cases, shipping handling
and vibration will relocate the material leading to loose
packing and movement within the case. It is important in
larger cases to fill voids sequentially as they are
formed in the building of the package. Eco Foam and other
such products are considered extremely unfriendly to the
end user.

Padpak® requires a special machine to
dispense crumpled Kraft sheets to lay into cases to fill
voids. This material is easy to recycle and considered
very friendly by the end user.

Kraft paper from rolls is commonly
used and requires no dispenser. Paper is crumpled into
the voids of the case by the operator. This material is
easy to recycle and considered very friendly by the end
user.

Bubble wrap is useful for wrapping
fragile objects but is relatively expensive as a void
fill. It is also not easy to recycle by the end-user

Corrugated inserts can be used for
filling and bracing. A modular mixed case system that
utilizes modular braces can save significantly on the use
of loose fill as well as providing isolation protection
between heavy and light objects.

Packing Method

When filling a mixed case order with void
fill in the case, place heavier and larger objects in the case
first, filling voids progressively in order to prevent later
migration of void fill. Products that crush easily should be
packed separately from those that can withstand crushing.

Variable Depth Cases

While unsuitable for all usages, a case
with multiple depth scores can be used to reduce the need for
void filling material and the amount of "air" being
shipped in the distribution chain, in some instances. Usually the
case is produced with the slots to the first depth bend and this
means that the pack must be cut down to any of the other depths
by the packers. This introduces sharp implements into the packing
section which is often regarded as unsuitable. The alternative of
slotting the case to the lowest depth means that the pack will be
significantly weaker than normal.

Die-cut designs can sometimes also be
employed, with or without internal fitments to reduce the need
for Void Filling Material. An example of this type of design is
the "Flip-back folder" a variant of FEFCO 0473.

Band strapping is often the best way to securely close Variable Depth packs.